Plug with anchored retaining packings for a cartridge for a water faucet

ABSTRACT

A plug with retaining packing for a water faucet cartridge where the packing is made in one piece on both sides of the plug. Both the portion of the packing that is on one side of the plug and the portion of the packing that is on the other side of the plug have a part of their surface in contact with and resting on the plug with respect to the axial direction of the plug and being connected to each other by at least one connection portion that extends substantially in an axial direction in a peripherally continuous manner or by sections through appropriate openings in the plug. The packing is formed and shaped on the plug by injecting an elastomer in the liquid state and cross-linking the elastomer.

FIELD OF THE INVENTION

This invention relates to a plug with retaining and sealing packing fora water faucet cartridge.

BACKGROUND OF THE INVENTION

A water faucet cartridge contains operating parts including means forthe control of water flow and handling members and is intended to beinserted in a removable and leak-proof fashion in the cavity of a waterfaucet body connected to pipes. A cartridge permits easy and rapidreplacement of operating parts when they have broken or when they havebecome worn out. The cartridge has a packing which, when the cartridgeis inserted into the body of the faucet, establishes a sealing hold withrespect to the bottom of the cavity of the faucet body. The plug alsoestablishes a sealing hold with respect to an internal member that is apart of the means which control the water flow such as, for example, afixed plate made of hard material which cooperates with a mobile platethat is operated by the handling members.

These seals have been conventionally established by packings whichextend through the plug and press against the bottom of the cavity ofthe faucet body against the fixed plate (a known and conventionalarrangement shown schematically in FIG. 1 of the drawings). Thisarrangement had the disadvantage that the contact pressure of thepacking was the same against the bottom of the cavity of the faucet bodyand against the fixed plate. This meant that in many cases an excessivemounting compression had to be applied to the fixed plate, saidexcessive compression obstructing the operation of the faucet.

This is why the use of two separate packings installed on both sides ofthe plug was resorted to. One packing acts against the bottom of thefaucet body, while the other packing acts against the fixed plate. Thismakes it possible to apply different compressions to the two packings (aknown and conventional arrangement illustrated schematically in FIG. 2of the drawings). However, it is easy to see that similar packingslodged in appropriate seats of the plug can be deformed or can beexpelled from their seats under high pressures or pressure surges suchas arise when the faucet is in operation. To prevent this disadvantageelastomers that are relatively rigid are used for packings, andrelatively high mounting compressions are used on the packings. Both ofthese factors impede the performance of the faucet. Provision forspecial configurations of the seats that receive the packings can bemade but these are expensive and are not always effective.

Another serious problem associated with these packings can be observedwhen a cartridge is assembled by means of automatic equipment, as is nowcustomary. The grasp and insertion of the packings in their seats callfor appropriate work stations and constitute an operation that is verydelicate due to the deformability of the packings and the rather poorprecision of their dimensions. Because of this packings ratherfrequently are improperly installed. This results in the equipmentcoming to a halt and manual action being required to remove thedefective cartridges. Furthermore, the packings that are intended forthe outside of the plug must be inserted manually after the completionof the cartridge, otherwise they would become detached during theassembly operations. These outside packings are also frequentlyseparated from the finished cartridge during transport.

One object of this invention is to provide a plug with retainingpackings for a faucet cartridge which, in addition to permitting theapplication of different assembly compressions on the two sides of theplug, also ensures that the packings cannot be deformed or expelled fromtheir seats even under maximum pressures or foreseeable pressure surges,and to substantially facilitate the mounting of the cartridge byautomatic equipment.

SUMMARY OF THE INVENTION

According to the present invention, the packing is made in one piece onboth sides of the plug. The portion of the packing that is on one sideof the plug and the portion of the packing that is on the other side ofthe plug have a portion of their surfaces resting against the plug withrespect to the axial direction of the plug and linked to each other byat least one connecting portion that extends primarily in the axialdirection. The packing is molded on the plug by injecting an elastomerin the liquid state and then cross-linking it.

Due to these features both portions (upper and lower) of the packing areable to accept the necessary assembly compression from the plug againstwhich a part of their surface rests. Thus, the possibility of applyingadequate, possibly different compressions upon the portions of packingsinstalled on the two sides of the plug is assured. At the same time, thepacking is positively anchored at the bottom of the cartridge and thelink between the two portions of the packing that are on the two sidesof the plug ensures that the portions themselves cannot be deformed orexpelled from their seats even when subjected to high stresses which arewithin the breaking strength of the material of which the packings aremade.

In many cases the packings can be made of an elastomer having high yieldcharacteristics, which is an advantage to the faucet's properperformance.

Making these packings by an injection procedure makes it possible toobtain the desired configurations, which in many cases could not beachieved in any other way and which would otherwise involve complexoperations. It is possible to provide packings with certainconfigurations that could not have heretofore been achieved in aconvenient fashion or that would have made the packings themselvesexcessively delicate. In particular, it is possible to provide thepacking shapes that exhibit differences in extension in variousdirections, and shapes that are considerably different on the two sidesof the plug. It is also possible to provide packings that are soresistant that they are not limited to operating only statically withoperationally immobile parts, but can function properly with anoperationally mobile part such as a stopper. This makes it possible toproduce cartridges with a simpler and more economical structure.

The fact that the packings are made on the plug itself avoids any andall operations requiring the assembly of the packings and thussimplifies mounting of the cartridges. In particular in automatedassembly the number of work stations can be reduced and the mostfrequent causes of equipment stoppage can be prevented.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a prior art shape of a plug withpacking;

FIG. 2 is a cross-sectional view of another prior art shape of a plugwith packing;

FIG. 3 is a side elevational cross-sectional view of a packing of theinstant invention mounted on a plug;

FIG. 4 is a view similar to FIG. 3 except showing a second embodiment ofa packing of the instant invention;

FIG. 5 is a view similar to FIG. 3 except showing a third embodiment ofa packing of the instant invention;

FIG. 6 is a view similar to FIG. 3 except showing a fourth embodiment ofa packing of the instant invention;

FIG. 7 is a top plan view taken along line VII--VII in FIG. 6;

FIG. 8 is a view similar to FIG. 3 except showing a fifth embodiment ofa packing of the instant invention;

FIG. 9 is a top plan view taken along line IX--IX in FIG. 8;

FIG. 10 is a view similar to FIG. 3 except showing a sixth embodiment ofa packing of the instant invention, this embodiment being a modificationof the fifth embodiment shown in FIGS. 8 and 9;

FIG. 11 is a top plan view taken along XI--XI in FIG. 10;

FIG. 12 is a view similar to FIG. 3 except showing a seventh embodimentof a packing of the instant invention;

FIG. 13 is a top plan view taken along line XIII--XIII in FIG. 12;

FIG. 14 is a view similar to FIG. 3 except showing an eighth embodimentof a packing of the instant invention;

FIG. 15 is a side elevational cross-sectional view of a ninth embodimentof a packing of the instant invention;

FIG. 16 is a side elevational cross sectional view of a cartridge, witha flat mobile plate in contact with the packing of the instantinventions;

FIG. 17 is a view similar to FIG. 16 except showing the operating handleand flat mobile plate in a different position;

FIG. 18 is a view similar to FIG. 16 except showing the operating handleand flat mobile plate in a different position; and

FIG. 19 is a view taken along line XIX--XIX in FIG. 18.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1 and 2 show a plug with prior art packings. Here and in thesuccessive figures the reference numeral 1 indicates the bottom of afaucet body cavity containing passages for water. The remaining parts ofthe faucet body are not shown, because they are of no relevance to thisinvention. In the figures the reference numeral 2 refers to the bottomof a cartridge and the reference numeral 3 refers to a fixeddistribution plate made of hard material constituting a part of the flowcontrol means in the cartridge. The other parts of the cartridge areomitted in FIGS. 1 to 15 because they are of no concern to thisinvention.

As shown in FIG. 1, prior art packings 4 are inserted through openingsin plug 2 to connect corresponding passages in the bottom 1 of thefaucet cavity and in fixed plate 3 providing a seal between both ofthese parts. In this case it is not possible to apply different assemblycompressions between packings 4 and bottom 1, and between packings 4 andfixed plate 3, as is often required.

In the prior art packing shown in FIG. 2 the above discusseddisadvantage is eliminated by employing separate packings 5 and 6 thatprovide a seal between plug 2 and bottom 1 of the faucet cavity andbetween plug 2 and fixed plate 3. It is thus possible to apply differentmounting compressions on packings 5 and 6. However, packings 5 and 6 areretained in their seats only by the respective mounting compressions,and in the presence of high working pressures and pressure surges theycan be deformed in the spaces existing between plug 2 and bottom 1 ofthe faucet body cavity and between plug 2 and fixed plate 3, or they canbe ejected from their seats through said spaces. To prevent this problemit has been proposed that seats that receive the packings haveparticular configurations. However, this is not reliable and not alwayssufficient. Furthermore, serious problems exist in the assembly of thecartridges because of the need for inserting packings in the seats ofthe plug.

FIG. 3 shows one embodiment of a plug with the packings anchored inaccordance with the present invention. In this case in each passageopening in plug 2 of the cartridge there is installed a sealing packingthat has an inferior portion 7 and a superior portion 8. Both portionsare linked by a portion 9 that extends axially through the opening ofplug 2. Preferably the inferior portion 7 and the superior portion 8have projections 10 and 11 that are disposed in corresponding cavitiesof plug 2.

Both the inferior portion 7 and the superior portion 8 of each packinghave a large portion of their surface abutting against plug 2 of thecartridge. Because of this these portions receive adequate compressionbetween plug 2 and bottom 1 of the faucet body cavity for portion 7 andbetween plug 2 and fixed plate 3 for portion 8. This is why the mountingcompressions applied to portions 7 and 8 of the packing can bedifferent. Thus, regardless of what the pressure or the pressure surgeapplied to the packing and acting inside said packing toward the outsidemay be, neither portion 7 nor portion 8 of the packing is deformed tothe outside nor ejected from its seat because it is positively retainedin its seat by the link through portion 9 with the other portion 8 or 7.When projections 10 and 11 are inserted in corresponding cavities in theplug they also collaborate in this positive retaining action.Projections 10 and 11, when present, can be continuous, they can bering-shaped, or they can exist only in sections.

As can be seen from FIG. 3 it would be very difficult to apply to plug 2a separate packing 7-11 having this shape and this application could notbe accomplished by automatic equipment. The production of this packingis easy and industrially convenient by proceeding in accordance with theinstant invention and molding it directly on plug 2 by injecting anelastomer in the liquid state into a suitable mold and cross-linking theelastomer. This procedure eliminates any packing mounting operation. Byproceeding in this way the shape of the packing can be selected asdesired even though it may be complex.

The embodiment illustrated in FIG. 4 is extremely similar to theembodiment illustrated in FIG. 3 from which it differs only by thepresence on the lower portion 7 and on the upper portion 8 of peripheralprojections 12 and 13 which are inserted in corresponding cavities ofplug 2. These projections, similar to projections 10 and 11 (which theycan replace), cooperate in anchoring the packing to plug 2. Theseprojections can also be continuous, ring-shaped, or in sections.

In the embodiment illustrated in FIG. 5, peripheral projections 12 and13 of the embodiment illustrated in FIG. 4 are replaced by portions 14that extend through the cavities of plug 2, connecting portions 7 and 8of the packing to each other. It is readily apparent that portions 14cannot extend continually along the entire periphery of the packing andmust be in sections that can be made in any number and any extent.Another embodiment of the portions in sections extending through theplug is shown in cross-section in FIG. 13. Portions 14 can also replaceportion 9 instead of being an addition thereto. It is obvious that suchan embodiment could not be produced except by the injection procedure ofthe instant invention.

In the embodiment illustrated in FIGS. 6 and 7 the packing still hasinferior portion 7 and superior portion 8 that have a part of theirsurfaces abutting against plug 2 and a connecting portion 9 that extendsaxially. However, portions 7 and 8 are also peripherally anchored toplug 2 due to their toothed configuration, as illustrated in FIG. 7. Theperipheral teeth of these portions can also be configured in an undercutfashion. Alternatively, a similar embodiment can be provided without theperipheral teeth. In this embodiment a rigid bushing 15 can be insertedinside connecting portion 9 of the packing.

Alternatively, the bushing illustrated in FIG. 6 and labeled 15, insteadof being a separate, rigid, inserted bushing, can be a part of plug 2and in such case connecting portion 9 need not be continuous but can bemade in sections and can extend through corresponding openings in plug2, as described above in conjunction with the embodiment illustrated inFIG. 5 and as substantially illustrated in FIG. 13.

FIGS. 8 and 9 illustrate how a plurality of packings of the typedescribed in the preceding embodiment (which in this embodiment do nothave any peripheral teeth) can be made during the injection procedure,providing for a single injection region 16 that communicates withportions 8 of all or part of the packings of plug 2. It is, however,possible to have several common injection points when expedient by theinjection technique.

This concept can be further extended, as illustrated in FIGS. 10 and 11,to mold on plug 2, together with the packings described in the precedingembodiment, a peripheral packing 17 that is adapted to seal the openingbetween plug 2 and wall 19 of the cartridge. For this purpose it issufficient to provide communication passages 18 between the injectionspaces of packings 7, 8 and 9 and a peripheral ring-shaped injectionspace for packing 17.

In the embodiment illustrated in FIGS. 12 and 13 inferior portion 7 andsuperior portion 8 are connected to each other by connecting portions 20which, in contrast to connecting portions 9 discussed earlier, are notcontinuous but are made up of sections and go through correspondingpassage openings in plug 2 similarly to the peripheral connectingportions 14 illustrated in FIG. 5. Packings that have this configurationcan also only be made by the injection procedure of this invention.

FIG. 14 illustrates a modification of the embodiment illustrated in FIG.12. In this case superior portion 38 of the packing is shaped like alip. Due to this configuration the packing assumes a "hydraulic effect"since its contact pressure with respect to fixed plate 3 is determinednot only by the mounting compression but also by the pressure exerted onlip 28 by the water. In this way, the contact pressure increases aswater pressure increases, automatically adapting to it so that themounting compression, which represents the minimum contact pressure oflip 28, can be set at a lower value. It is, of course, to be understoodthat where considered advisable inferior portion 7 of the packing canalso be made in the form of a lip similar to superior portion 28.

FIG. 15 illustrates another embodiment of the invention. Certainconventional cartridges are provided with lower connections that extendinto seats formed in the bottom of the faucet body cavity, providing asealing hold by means of packings applied to the connections andreceiving a water thrust that depends on the water pressure and, ifapplicable, on the pressure of a spring. With the present invention itis possible to make said connections and their packings in a singleoperation during the injection of the packings of the plug. In theembodiment illustrated in FIG. 15, each of the packings of the plug isbasically of the type shown in FIG. 5, but its inferior portion 7extends peripherally to form a sleeve 27 and rests against the inferiorportions 7 of the packings. This embodiment illustrates how theinvention can be used advantageously to facilitate the production ofcertain special cartridges for faucets and make them more economical.

It should be noted that an embodiment similar to the one in FIG. 15 butturned upside down makes it possible to produce connections that extendupwardly from packing 2 of the cartridge and that are adapted to engagein corresponding cavities of fixed plate 3.

Reference has already been made to the fact that the particularresistance of the packings of the plug of a cartridge enable them tofunction not only in a static fashion, that is to say to establish aseal between immobile operating parts, but also to function in a dynamicfashion, that is to say to establish a seal of the plug with respect toan operationally mobile part such as a stopper. The stability of shapeof the packings of the plug of a cartridge makes it possible to givethem shapes that have different lengths in various directions, in otherwords elongated shapes that are different from circular shapes and alsoshapes that are quite different on the two sides of the plug of thecartridge. These features of the instant invention are illustrated inFIGS. 16 to 19.

The cartridge for a mixing faucet shown in these figures, particularlyin the vertical cross-section in FIGS. 16 to 18 which illustrate it invarious operating positions, comprises a shell 30 with a perimeter wall31 to which is connected a plug 32 with the interposition of a packing29. In the upper part of shell 30 is rotatably mounted a supporting ring33 on which is pivoted a lever 34 coupled to a slide 35. This slide hasa flat stopper 36 that can be made of, for example, inoxidizable steel.The stopper 36 has passage openings that communicate with each other inthe inside space of slide 35. Stopper 36 is intended to cooperatedirectly with packings formed on plug 32.

As shown in FIG. 19, superior portion 8 of a packing for an outletopening (and thus the corresponding inferior portion 7) can be circular,while superior portion 38 of the packings for the inlet openings have,for example, a "banana" shape or the like which permits flow controlthat is much more accurate than the one attainable with circular inletopenings. Packings having this shape made in the traditional andconventional fashion would be readily broken by stopper 36 when it movesfrom a position of occlusion (FIG. 16) to a position of completeadmission (FIG. 17) passing through intermediate positions (FIG. 18).The effective anchorage of the plug of the packings of this invention,on the other hand, enables packings having this shape to operateproperly in contact with the mobile stopper without being dislocated ordeformed.

Furthermore, since the inferior portions 37 of the packings for theinlet openings need not have a shape different from a circular shape,they can have a circular shape and can be connected to banana shapedsuperior portions 38 through connecting walls 39. All the packings andpacking portions 7, 8, 37, 38, 39 and 29 of plug 2, or part of them, canbe made collectively from a single injection point 16 (or from severalcommon injection points) and through ducts 18, as discussed earlier inconnection with FIGS. 8-11. Finally, reinforcing bushings 15 can beintroduced into packings 7-9 and 37-39.

A cartridge such as the one shown in FIGS. 16-19 offers performance thatsubstantially corresponds to those of a similar cartridge employing apair of plates made of hard material, one fixed and one mobile, and isconsiderably less expensive and less bulky.

Other modifications and variations of the present invention are possiblein light of the above teachings. It is, therefore, to be understood thatchanges may be made in the particular embodiments of the inventiondescribed which are within the full intended scope of the invention asdefined by the appended claims.

What is claimed is:
 1. Plug with sealing packing for a water faucetcartridge comprising the sealing packing being in one piece on bothsides of the plug, wherein both the portion of the packing that is onone side of the plug and the portion of the packing that is on the otherside of the plug have at least a portion of their surface in contactwith the plug and are connected to each other by at least one connectingportion.
 2. Plug with packing of claim 1 wherein said connecting portionextending between the portions of packings that are on the two sides ofthe plug is connected to them along their internal periphery.
 3. Plugwith packing of claim 2 wherein said connecting portion is continuous.4. Plug with packing of claim 2 wherein said connecting portion iscomprised of sections.
 5. Plug with packing of claim 1 wherein saidconnecting portion is linked to the portions of the packings that are onthe two sides of the plug in regions different from their internalperiphery and extends in sections through openings in the plug.
 6. Plugwith packing of claim 1 wherein at least one of said packing portionsthat are on the two sides of the plug has projections which are adaptedto be inserted in corresponding openings in the plug.
 7. Plug withpacking of claim 1 wherein at least one of said packing portions thatare on the two sides of the plug has peripheral teeth.
 8. Plug withpacking of claim 1 wherein various packings of the plug have connectingsections that permit their collective injection from one or severalcommon injection points.
 9. Plug with packing of claim 8 comprising aperipheral ring-shaped packing, which has at least one connectingsection to at least one other packing of the plug so as to be injectedcollectively with it from one or several common injection points. 10.Plug with packings of claim 1 wherein at least one packing portion on atleast one side of the plug has the shape of a lid.
 11. Plug with packingof claim 1 wherein the packing portion on the side of the plug facingthe bottom of the faucet body cavity forms a protruding connection withretaining projections adapted to be inserted in a corresponding seat ofthe bottom of the faucet body cavity.
 12. Plug with packing of claim 11wherein said protruding connection is arranged to receive a spring. 13.Plug with packing of claim 1 wherein the packing portion on the side ofthe plug facing toward the inside of the cartridge forms a protrudingconnection with retaining projections adapted to be inserted in acorresponding seat of a member that is a part of the flow control means.14. Plug with packing of claim 1 wherein said packing portion that is atleast on one side of the plug has a substantially circular shape. 15.Plug with packing of claim 1 wherein said packing portion that is on oneside of the plug has a shape that has different extension in variousdirections.
 16. Plug with packing of claim 1 wherein said packingportion that is at least on one side of the plug has a shape that issubstantially different from the shape of the corresponding packingportion that is on the other side of the plug, said packing portionsbeing connected to each other by connecting portions that extend in anon-axial direction.